Stretch composites and methods of making the composites

• US 9,404,215 B2
• Filed: 06/07/2013
• Issued: 08/02/2016
• Est. Priority Date: 11/05/2001
• Status: Expired due to Term

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Desai, Fred Naval, Dalal, Urmish Popatlal, Hamersky, Mark William, Smith, Steven Daryl
• Primary Examiner(s): Cole, Elizabeth M
• Application Number:
  US13/912,727
• Publication Number:
  US 20130273338A1
• Time in Patent Office: 1,152 Days
• Field of Search: 442/329, 428/107, 428/108, 428/110
• US Class Current: 1/1
• CPC Class Codes: A61F 13/15593 having elastic ribbons fixed thereto; Devices for applying the ribbons
• CPC Class Codes: A61F 13/4902 characterised by the elastic material
• CPC Class Codes: A61F 2013/15284 characterized by quantifiable properties
• CPC Class Codes: B29C 55/08 transverse to the direction of feed
• CPC Class Codes: B29C 55/18 by squeezing between surfaces, e.g. rollers
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 53/025 modified
• CPC Class Codes: D06N 3/045 with polyolefin or polystyrene (co-)polymers
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/2481 including layer of mechanically interengaged strands, strand-portions or strand-like strips
• CPC Class Codes: Y10T 428/24851 Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/269 including synthetic resin or polymer layer or component

Abstract

A stretch composite having one or more elastomeric members disposed on at least one region of an extensible fibrous substrate to provide stretch properties to a targeted region of the substrate. The composite has been incrementally stretched to at least partially break up the structure of the substrate in order to reduce its resistance to stretch. The stretch composites are useful for disposable and durable articles, such as disposable absorbent articles including diapers, pull-on diapers, training pants, incontinence briefs, catamenial garments, baby bibs, and the like, and durable articles like garments including sportswear, outerwear and the like. Also disclosed are methods of forming such stretch composites.

Claims

1. A stretch composite comprising:

an extensible first substrate having one or more first thermoplastic elastomeric members disposed on at least a portion of the substrate to form a first elasticized region,

wherein the first thermoplastic elastomeric member comprises a thermoplastic elastomer and a phase change solvent having the general formula;

R′

-L_y-(Q-L_x)_n-1-Q-L_y-R;

 

 

(I)

R′

-L_y-(Q-L_x)_n-R;

 

 

(II)

R′

-(Q-L_x)_n-R;

 

 

(III)

R′

-(Q-L_x)_n-1-Q-L_y-R;

 

 

(IV)

R′

-(Q-L_x)_n-1-Q-R;

or 

 

(V)

a mixture thereof;

wherein Q is a para-ring substituted difunctional aromatic moiety, and wherein the substitutions are in the 1,4 positions;

L is CH₂;

R and R′

are the same or different and are independently selected from H, CH₃, COOH, CONHR₁, CONR₁R₂, NHR₃, NR₃R₄, hydroxy, or C₁-C₃₀ alkoxy;

wherein R₁, R₂, R₃ and R₄ are the same or different and are independently selected from H or linear or branched alkyl from C₁-C₃₀;

x is an integer from 1 to 30;

y is an integer from 1 to 30; and

n is an integer from 1 to 7;

wherein the phase change solvent has a phase change in a temperature range from 40°

C. to about 250°

C.; and

wherein the first thermoplastic elastomeric member has an average width greater than about 0.2 mm.

2. The composite of claim 1, wherein the composite comprises a plurality of rectilinear or curvilinear first thermoplastic elastomeric members.

3. The composite of claim 2 wherein at least two of the first thermoplastic elastomeric members are non-parallel.

4. The composite of claim 1 further comprising a second substrate in a facing relationship with the first substrate and the elastomeric members are disposed between the substrates.

5. The composite of claim 1 further comprising one or more second thermoplastic elastomeric members disposed in a second portion of the substrate to form a second elasticized region.

6. The composite of claim 5, wherein the first elasticized region and the second elasticized region are adjacent or at least partially overlapping.

7. The composite of claim 5, wherein at least a portion of the first or the second elasticized region has been incrementally stretched.

8. The composite of claim 5, wherein the composite comprises a plurality of rectilinear or curvilinear second thermoplastic elastomeric members.

9. The composite of claim 5, wherein at least one of the first thermoplastic elastomeric members and at least one of the second thermoplastic elastomeric members are non-parallel with respect to each other.

10. The composite of claim 5 further comprising a second substrate in a facing relationship with the first substrate and the elastomeric members are disposed between the substrates.

13. The composite of claim 1 comprising at least a portion of an absorbent article selected from the group consisting of an elasticized waist region, an elasticized cuff region, an elasticized side panel, an elastic ear portion, an elasticized outer cover, an elasticated topsheet, a fastener system, and combinations thereof.

14. The composite of claim 10 comprising at least a portion of an absorbent article selected from the group consisting of an elasticized waist region, an elasticized cuff region, an elasticized side panel, an elastic ear portion, an elasticized outercover, an elasticated topsheet, a fastener system, and combinations thereof.

16. The composite of claim 1 wherein Q is selected from the group consisting of terephthalic, naphthalic, phenolic, phenyl and biphenyl having the following formulae:

17. The composite of claim 1 wherein Q is substituted on the aromatic ring with one or more substituents selected from H, C₁-C₃₀ alkyl, COOH, CONHR₅, CONR₅R₆, NHR₇, NR₇R₈, hydroxy, C₁-C₃₀ alkoxy, SO₃H, or halogen;

wherein R₅, R₆, R₇ and R₈ are the same or different and are independently selected from H or linear or branched alkyl from C₁-C₃₀.

18. The composite of claim 1 wherein n is an integer from 3 to 7.

11. A stretch composite comprising:

an extensible fibrous substrate having a plurality of first thermoplastic elastomeric members disposed on a first elasticized region; and

a plurality of second thermoplastic elastomeric members disposed on a second elasticized region;

wherein the first and the second thermoplastic elastomeric members differ in a property selected from the group consisting of elasticity, melt viscosity, composition, shape, pattern, add-on level, and combinations thereof;

wherein the first thermoplastic elastomeric member comprises a thermoplastic elastomer and a phase change solvent having the general formula;

R′

-L_y-(Q-L_x)_n-1-Q-L_y-R;

 

 

(I)

R′

-L_y-(Q-L_x)_n-R;

 

 

(II)

R′

-(Q-L_x)_n-R;

 

 

(III)

R′

-(Q-L_x)_n-1-Q-L_yR;

 

 

(IV)

R′

-(Q-L_x)_n-1-Q-R;

or 

 

(V)

a mixture thereof;

wherein Q is a para-ring substituted difunctional aromatic moiety, and

wherein the substitutions are in the 1,4 positions;

L is CH₂;

R and R′

are the same or different and are independently selected from H, CH₃, COOH, CONHR₁, CONR₁R₂, NHR₃, NR₃R₄, hydroxy, or C₁-C₃₀ alkoxy;

wherein R₁, R₂, R₃ and R₄ are the same or different and are independently selected from H or linear or branched alkyl from C₁-C₃₀;

x is an integer from 1 to 30;

y is an integer from 1 to 30; and

n is an integer from 1 to 7;

wherein the phase change solvent has a phase change in a temperature range from 40°

C. to about 250°

C.; and

wherein at least a portion of the composite within the first or the second elasticized region has been incrementally stretched resulting in permanent elongation of the substrate in said portion.

12. The composite of claim 11 further comprising a second substrate in a facing relationship with the first substrate and the elastomeric members are disposed between the substrates.

15. The composite of claim 11 comprising at least a portion of an absorbent article selected from the group consisting of an elasticized waist region, an elasticized cuff region, an elasticized side panel, an elastic ear portion, an elasticized outercover, an elasticated topsheet, a fastener system, and combinations thereof.

19. The composite of claim 11 wherein Q is selected from the group consisting of terephthalic, naphthalic, phenolic, phenyl and biphenyl having the following formulae:

20. The composite of claim 11 wherein Q is substituted on the aromatic ring with one or more substituents selected from H, C₁-C₃₀ alkyl, COOH, CONHR₅, CONR₅R₆, NHR₇, NR₇R₈, hydroxy, C₁-C₃₀ alkoxy, SO₃H, or halogen;

wherein R₅, R₆, R₇ and R₈ are the same or different and are independently selected from H or linear or branched alkyl from C₁-C₃₀.

21. The composite of claim 11 wherein n is an integer from 3 to 7.